Miller MTT-1512HR Manuel utilisateur

March

1988

FORM:

OM-i

559

Millerﬁ

ALE

COpy

~ETURN

FOLDER

Effective

With

Style

No.

JJ-23

MODEL

MTT-1512HR

MTT-1525HR

MTT-1512NR

MTT-1525NR

MTF-1512VHR

MU-i

525VH

MU-1512VNR

MU-i

525

MU-i

512

MU-1525HF

MU-1512NF

MU-i

525N

MU-1512VHF

MU-i

525

MU-1512VNF

MU-i

525

OWNERS

MANUAL

IMPORTANT

Read

and

understand

the

entire

contents

both

this

Miller

Electric

Mfg.Co.

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

the

safety

material

throughout

both

manuals,

before

in-

~o.

Box

1079

stalling,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

Appleton,

54912

USA

Te1

414-734-9821

safe

operation

welding

equipment.

not

allow

untrained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

PRINTED

U.S.A.

ADOmONAL

COPY

PRICE

CENTS

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

16.

1988

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY

Subject

the

terms

and

condi-

the

case

Millers

breach

warranty

any

other

duty

tions

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

with

respect

the

quality

any

goods,

the

exclusive

remedies

warrants

its

Distributor/Dealer

that

all

new

and

unused

therefore

shall

be,

Millers

option

(1)

repair

(2)

replacement

Equipment

furnished

Miller

free

from

defect

workman-

or,

where

authorized

writing

Miller

appropriate

cases,

(3)

ship

and

material

the

time

and

place

delivery

Miller.

the

reasonable

cost

repair

replacement

authorized

warranty

made

Miller

with

respect

engines,

trade

Miller

service

station

(4)

payment

credit for

the

purchase

accessories

other

items

manufactured

others.

Such

price

(less

reasonable

depreciation

based

upon

actualuse)

upon

engines,

trade

accessories

and

other

items

are

sold

subject

return

the

goods

Customers

risk

and

expense.

MILLERs

the

warranties

their

respective

manufacturers,

any

All

option

repair

replacement

will

F.O.B.,

Factory,

engines

are

warranted

their

manufacturer

for

one

year

from

Appleton,

Wisconsin,

F.O.B.,

MILLER

authorized

service

date

original

purchase,

except

Tecumseh

engines

which

facality,

therefore,

compensation

for

transportation

costs

have

two

year

warranty.

any

kind

will

allowed.

Upon

receipt

notice

apparent

defect

failure,

Miller

shall

instruct

the

claimant

the

warranty



Except

specified

below,

Millers

warranty

does

not

apply

claim

procedures

followed.

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

that

come

contact

with

the

welding

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

wire

including

nozzles

and

nozzle

insulators

where

failure

does

ANY

IMPUED

WARRANTY,

GUARANTY

REPRESENTA

not

result

from

defect

workmanship

material.

T1ON

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

Miller

shall

required

honorwarranty

claims

war-

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

ranted

Equipment

the

event

failure

resulting

from

defect

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

~

within

the

following

periods

from

the

date

delivery

Equip-

ANY

IMPUED

WARRANTY

MERCHANTABIUTY

ment

the

original

user:

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

Arc

welders,

p~r

sources,

robots,

and

components

year

CLUDED

AND

DISCLAIMED

MILLER.

Load

banks

year

Original

main

power

rectifiers

years

(labor

year

only)

EXCEPT

EXPRESSLY

PROVIDED

MILLER

i.)

Allweldingguns,feeder/gunsandtorches

90days

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

All

other

Millermatic

Feeders

year

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

Replacement

repair

parts,

exclusive

labor

days

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

~

Batteries

months

EXPERIENCED

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

provided

that

Miller

notified

writing

within

thirty

(30)

days

CONSUMER

USE.

MILLERS

WARRANTIES

NOT

EXTEND

the

date

such

failure.

TO,

AND

RESELLER

AUTHORIZED

EXTEND

matter

general

policy

ony,

Miller

may

honor

claims

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

submitted

the

original

user

within

the

foregoing

periods.



......

..-...

-...

Since

cess,

WARNING

SECTION

_________

UNSAFE

PROCEDURES

PRAC

TIGES

can

cause

serious

personal

injury

death.



Read,

understand,

and

ALL

these

safety

rules

before

installing,

operating,

servicing

this

equipment.



sure

that

all

end

users

this

equipment,

the

operator

and

helpers,

read

and

understand

these

safety

rules.

PREVENT

ELECTRIC

SHOCK

Touching

live

electrical

parts

can

cause

severe

burns

the

body

fatal

shock.

Severity

electrical

shock

determined

the

path

and

amount

current

through

the

body.

Therefore:

not

touch

live

electrical

parts.

not

work

wet

damp

areas.

Wear

dry

insulating

gloves

and

body

protection.

Disconnect

all

power

before

installing

servic

ing

this

equipment.

Turn

off

all

equipment

when

not

use.

Properly

install

and

ground

the

welding

power

source

according

its

Owners

Manual

and

all

applicable

codes.

not

use

worn

damaged

cables

that

are

too

small

poorly

spliced.

not

wrap

cabes

around

your

body.

not

touch

electrode

and

any

grounded

object

circuit

the

same

time.

Use

only

well-maintained

equipment.

Repair

replace

damaged

parts

once.

PROVIDE

PROTECTION

FROM

FUMES

AND

GASES

Breathing

welding

fumes

and

gases

can

hazardous

your

health.

Keep

your

head

out

the

fumes.

Use

adequate

ventilation

the

work

area

keep

fumes

and

gases

from

your

breathing

zone

and

the

general

work

area.

ventilation

inadequate,

use an

approved

breathing

device.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instructions

for

any

materials

used.

SAFETY

RULES

-3.

PROTECT

EYES

AND

SKIN

FROM

ARC

RAYS;

PROTECT

EARS

FROM

NOISE

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Wear

welding

helmet

fitted

with

proper

filter

lens

(see

ANSI

Z49.1

for

detailed

information).

Use

protective

screens

barriers

protect

others

from

flash

and

glare.

Wear

protective

clothing

and

foot

protection.

Always

wear

safety

glasses

safety

goggles

work

area.

-4.

PREVENT

FIRES

AND

BURNS

The

hot

workpiece,

hot

equipment,

other

hot

metal,

spatter,

and

arc

sparks

can

cause

fires

and

burns.

Wear

correct

eye,

face,

and

body

protection

the

work

area.

Allow

work

and

equipment

cool

before

handl

ing.

not

weld

near

combustible

material.

Watch

for

fire,

and

keep

fire

extinguisher

near

by.

For

additional

information,

refer

NFPA

Stan

dard

Fire

Prevention

Use

Cutting

and

Welding

Processes,

available

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

PROTECT

COMPRESSED

GAS

CYLINDERS

gas

cylinders

are

normally

part

the

welding

pro

sure

treat

them

carefully.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

Install

and

secure

cylinders

that

they

cannot

fall

tip

over

fastening

them

mounting

bracket,

wall,

other

stationary

support.

Keep

cylinders

away

from

any

welding

other

electrical

circuits.

Never

allow

welding

electrode

touch

any

cylinder.

aM-i

559

Page

-6.

PROVIDE

PROTECTION

FOR

SPECIAL

ITU

ATIO

not

weld

Cut

containers

materials

which

have

held

been

contact

with

hazardous

substances

unless

they

are

properly

cleaned

and

inspected.

not

weld

cut

painted

plated

parts

unless

special

ventilation

provided

remove

highly

toxic

fumes

gases.

Since

welding

can

affect

pacemakers,

keep

all

pacemaker

wearers

out

the

work

area.

Have

them

consult

doctor

before

coming

near

welding

operation.

PROVIDE

PROPER

EQUIPMENT

MAINTENANCE

Improperly

maintained

equipment

can

result

poor

work,

but

most

importantly

can

cause

physical

injury

death

through

fires

electrical

shock.

Therefore:

Always

have

qualified

personnel

perform

the

stallation,

troubleshooting,

and

maintenance

work.

not

perform

any

electrical

work

unless

you

are

fully

qualified.

Before

performing

any

maintenance

work

inside

power

supply,

disconnect

the

power

supply

form

the

electrical

power

source.

Maintain

cables,

grounding

wire,

connections,

power

cord,

and

power

supply

safe

working

order.

not

operate

any

equipment

ques

tionable

condition.

not

abuse

any

equipment

accessories.

Keep

equipment

away

from

heat

sources

such

furnaces,

wet

conditions

such

water

puddles,

oil

grease,

corrosive

atmospheres,

and

incle

ment

weather.

Keep

all

safety

devices,

guards,

panels,

and

covers

position

and

good

repair.

Use

equipment

for

its

intended

purpose.

not

modify

any

manner.

-8.

ADDITIONAL

SAFETY

INFORMATION

For

information

safe

practices

for

setting

and

operating

electric

welding

and

cutting

equipment

and

good

working

habits,

ask

your

welding

equip

ment

supplier.

The

following

publications,

which

are

available

from

the

American

Welding

Society,

550

N.W.

LeJuene

Rd.,

Miami,

33126,

are

recommend

you:

Safety

Welding

and

Cutting

AWS

Z49.1

(ANSI)

Recommended

Safe

Practices

for

Gas-Shielded

Arc

Welding

AWS

A6.1

Recommended

Safe

Practices

for

the

Prepara

tion

for

Welding

and

Cutting

Containers

and

Piping

That

Have

Held

Hazardous

Substances

AWS

F4.1

NFPA

Standard

516,

Fire

Prevention

Use

Cutting

and

Welding

Processes,

available

from

the

National

Fire

Protection

Association,

Bat

terymarch

Park,

Quincy,

02269.

NFPA

Standard

70,

National

Electrical

Code,

available

from

the

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

02269.

ANSI

Standard

Z87.1,

Safe

Practice

for

cupation

and

Educational

Eye

and

Face

Protec

tion,

available

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

10018.

OSHA

Standard

CFR,

Part

1910,

Subpart

Welding,

Cutting,

and

Brazing,

available

from

the

Superintendent

Documents,

U.S.

Govern

ment

Printing

Office,

Washington,

20402.

CSA

Standard

W117.2,

Code

for

Safety

Welding

and

Cutting,

available

from

the

Cana

dian

Standards

Association,

178

Rexdale

Blvd.,

Rexdale,

Ontario,

Canada

M9W

R3.

See

also

the

Standards

Booklet

Index

the

welding

power

source

Owners

Manual.

OM-1559

Page

SECTION

INTRODUCTION

Rated

with

Gas

Lens

Collet

Body

Figure

Specifications

-2.

GENERAL

INFORMATION

AND

SAFETY

General

Safety

Miller

TIG/GTAW

Torch

Ampere

Rating:

150

Amperes

12.5

ft.

(3.8

Cable

ft.

(7.6

Cable

High

Flex

Cable

piece

assembly)

High

Performance

Cable

piece

assembly)

Rigid

Head

Flexible

Head

Gas

Valve

Ampere

Rating

Model

100%

Duty

Cycle

DCEN:

ACHF

Tungsten

Size

Capacity

Cable

£~~h

Torch

Body

Cooling

Method

Weight

Net

Ship

MTT-1512HR

MTT-1512HF

MTr-1512VHF

2.5

lbs.

(1.1

kg)

3.0

lbs.

(1.4

kg)

MTT-1512VHR

MTT-1512NR

MTT-1512NF

12.5

ft.

(3.8

Length:

8.0

in.

(203.0

mm)

3.0

lbs.

3.5

lbs.

MTT-1512VNR

MTT1512VNF

MTT-1525HR

MTT-1525HF

150

Amperes

With

Argon

.020

thru

1/8

in.

(0.5

thru

3.2

mm)

Handle

Diameter:

0.9

in.

(22.9

mm)

Weight:

4.5

oz.

(127.6

Air

(1.4

kg)

(1.6

kg)

4.5

lbs.

5.0

lbs.

MTT-1525VHR

(2.0

kg)

(2.3

kg)

MTT-1525VHF

MIT-i

525NR

ft.

(7.6

MTT-i

525NF

5.5

lbs~

6.0

lbs.

MTT-1525VNR

MIT-i

525VNF

(2.5

kg)

(2.7

kg)

CAUTION

DUTY

CYCLE

The

duty

cycle

welding

torch

the

percentage

ten

minute

period

that

torch

can

operated

given

load.

This

torch

rated

100%

duty

cycle

using

argon

shielding

gas.

This

means

that

the

torch

can

operated

rated

load

con

ditions

continuously.

EXCEEDING

THE

RATED

AMPERAGE

and

duty

cycle

can

result

damage

the

torch.



not

exceed

rated

amperage

and

duty

cycle

stated

Figure

2-1.

statements

include

installation,

operation,

and

maintenance

procedures

practices

which

not

carefully

followed

could

result

minor

personal

injury

damage

this

equipment.

third

signal

word,

Il~I~s]

highlights

instruc

tions

which

need

special

emphasis

obtain

the

most

efficient

operation

this

equipment.

RECEIVING

HANDLING

Before

installing

this

equipment,

clean

all

packing

material

from

around

the

unit,

and

carefully

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

damage

that

may

have

occurred

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

will

furnished

the

manufacturer

request

occasion

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

is.

essential

that

Model

Description

and

Style

Numbers

the

equipment

supplied.

The

style

number

located

label

under

the

torch

handle.

DESCRIPTION

This

torch

specifically

for

use

with

the

Gas

Tungsten

Arc

Welding

(GTAW)

pro

cess.

The

alphanumeric

model

designation

refers

the

following:

Information

presented

this

manual

and

various

labels,

tags,

and

plates

the

unit

pertains

equip

ment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

read,

understood,

and

followed

for

the

safe

and

effective

use

this

equip

ment.

The

installation,

operation,

maintenance,

and

troubleshooting

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

others.

Therefore,

this

equipment

installed,

operated,

and

maintained

only

qualified

persons

accordance

with

this

manual

and

all

plicable

codes

such

as,

but

not

limited

to,

those

listed

the

end

Section

Safety

Rules.

Safety

instructions

specifically

pertaining

this

unit

pear

throughout

this

manual

highlighted

the

signal

words

____________

and

___________

which

identify

different

levels

hazard.

____________statements

include

installation,

operation,

and

maintenance

procedures

practices

which

not

carefully

followed

could

result

serious

personal

injury

loss

life.

WARNING

CAUTION

OM-1559

Page3

Assemble

torch

body

follows:

SECTION

INSTALLATION

Instafl

collet

body

into

torch

body

making

sure

heat

shield

place.

Install

cup

onto

collet

body.

Install

standard

collet,

slotted

end

first,

through

back

torch

body

into

collet

body.

using

reverse

collet,

install

collet

with

slotted

end

toward

backcap.

Install

backcap

and

0-ring

(supplied

backcap)

onto

torch

body.

Install

properly

prepared

tungsten

electrode

(see

Section

5-4)

through

front

collet

body

posi

tion

electrode

tip

outside

cup

rim.

Securely

tighten

backcap.

-2.

GAS

HOSE

CONNECTIONS

AND

GAS

VALVE

(If

applicable)

The

high

flex

cable

contains

the

power

cable

within

the

gas

hose.

The

high

flex

cable

has

3/8-24

male

right-

hand

fitting

(Figure

3-1).

install

high

flex

cable,

connect

high

flex

cable

fitting

power

cable

adapter.

Connect

suitable

length

gas

hose

from

power

cable

adapter

gas

valve

outlet

regulator/flowmeter

(Figures

3-2

and

3-3).

High

Performance

Cable

Assembly

The

high

performance

cable

assemby

has

separate

power

cable

and

gas

hose.

The

gas

hose

has

5/8-18

male

right-hand

fitting

(Figure

3-1).

install

gas

hose,

connect

gas

hose

fitting

gas

valve

outlet

regulator/flowmeter.

Connect

gas

hose

(extra

hose

not

supplied)

from

gas

valve

inlet

regulator/flowmeter

(Figures

3-2

and

3-3).

0-ring

Collate

Torch

Body

Collet

Short

Backcap

Tungsten

Eiectrode

Power

Cable

Connector

Gas

Valve

applicable)

9~.*__

0-ring

Power

Cable~

Adapter

Handle

Gas

Hose

Fitting

High

Flex

Cable

Fitting

WARNING

Required

Consumables

and

Accessories

*Obthin

from

Welding

Equipment

Supplier

Figure

Torch

Components

__________

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

disconnect

input

power

employing

lockout/tagging

pro

cedures

before

installing

torch.

Loc~.out/tagging

procedures

consist

padlocking

line

dis

onnect

switch

open

position,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnecting

device.

TA-120

873

readjust

electrode,

loosen

backcap.

IMPORTANT

______________

general

rule,

electrode

extension

should

equal

electrode

diameter;

exact

electrode

exten

s/on

may

va,y

according

application.

TORCH

BODY

(Figure

3-1)

The

torch

body

shipped

requiring

consumables

and

accessories

diated

Figure

3-1:

cup,

collet

body,

collet,

power

cable

adapter

(with

High

Flex

Cable

only),

and

tungsten

electrode.

IMPORTANT

______________

power

source

not

equipped

with

gas

valve,

torch

gas

valve

required.

install

gas

hose,

connect

gas

hose

fitting

regulator/flowmeter.

extra

hose

may

required

make

connection.

High

Flex

Cable

Assembly

OM-1

559

Page

Torch

Work

Clamp

Power

Cable

Adapter

Gas

Power

Source

Gas

Work

Power

Clamp

Adapter

Regulator/Flowmeter

Power

Source

Work

Clamp

High

Flex

Cable

Assembly

Gas

Power

Connector

High

Peformance

Cable

Assembly

Figure

GTAW

Torch

Connection

Diagram

For

Models

With

Gas

Valve

Gas

Cylinder

TA-120

824

Torch

Regulator!

Flowmeter

Torch

Power

Source

Power

Source

Gas

Valve

High

Flex

Cable

Assembly

Work

Clamp

Gas

Power

Cable

Gas

Connector

Valve

High

Performance

Cable

Assembly

Figure

GTAW

Torch

Connection

Diagram

For

Models

Without

Gas

Valve

TA-120

824

OM-1559

Page

Torch

Gas

Valve

Operation

(If

Applicable)

The

gas

valve

allows

gas

flow

control

the

torch.

one-half

turn

counterclockwise

opens

the

gas

valve,

and

one-half

turn

cJockwise

closes

the

valve.

The

gas

valve

allows

control

gas

postf

low

time,

~he

length

time

gas

flows

after

the

arc

extinguish

ed.

Insufficient

gas

postflow

results

oxidized

(black)

electrode

surface.

oxidized

electrode

were

used,

the

black

surface

would

contaminate

the

weld

and

cause

poor

arc

direction.

IMPORTANT

_____________

general

rule,

allow

seconds

gas

pos(flow

time

per

100

amperes

weld.

current

before

closing

valve.

-3.

POWER

CABLE

CONNECTION

(Figures

3-1,

3-2.

and

3-3)

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

disconnect

input

power

employing

lockout/tagging

pro

cedures

before

installing

torch.

WARNING:

Lockout/tagging

procedures

consist

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnecting

device.

High

Flex

Cable

Assembly

The

high

flex

cable

assembly

contains

the

power

cable

within

the

gas

hose.

The

high

flex

cable

has

3/8-24

male

right-hand

fitting

(Figure

3-1).

install

high

flex

cable,

connect

high

flex

cable

fitting

power

cable

adapter

(see

Section

3-2A).

Connect

power

cable

adapter

weld

output

terminal

(Figures

3-2

and

3-3).

High

Performance

Cable

Assembly

The

high

performance

cable

assembly

has

separate

power

cable

and

gas

hose.

install

power

cable,

connect

power

cable

connector

weld

output

terminal

(Figures

3-2

and

3-3).

SECTION

SEQUENCE

OPERATION

WARNING

_________

ELECTRIC

SHOCK

can

kill.



not

touch

five

electrical

parts.



Keep

all

covers

and

handle

place

white

operating.

ARC

RAYS,

SPARKS,

AND

HOT

SURFACES

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

correct

eye,

ear,

and

body

protection.

FUMES

AND

GASES

can

seriously

harm

your

health.



Ventilate

keep

from

breathing

fumes

and

gases.



ventilation

inadequate,

use

approved

breathing

apparatus.

METAL,

SPATTER,

AND

SLAG

can

cause

fire

burns.

Watch

for

fire.

Have

fire

extinquisher

nearby,

and

know

how

use.



Allow

work

and

equipment

cool

before

handl

ing.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.



Wearers

should

consult

with

their

doctor

before

going

near

arc

welding,

gouging,

spot

welding

operations.

See

Section

Safety

Rules

for

additional

safety

infor

mation.

Set

power

source

for

desired

welding

amperage.

Wear

dry

insulating

clothing

and

gloves

and

welding

helmet

with

proper

filter

lens

according

ANSI

Z49.1.

Energize

welding

power

source.

Set

gas

flow

desired

level

(requires

open

gas

valve).

IMPORTANT:

_________

Purge

gas

hose

clear

hose

air,

moisture,

any

other

contaminants.

Allow

gas

flow

minutes

new

torch;

seconds

thereafter.

IMPORTANT

general

rule,

allow

seconds

gas

postflow

time

per

100

amperes

weld

current

before

closing

valve.

Turn

off

welding

power

source.

GAS

TUNGSTEN

ARC

WELDING

(GTAW)

Install

and

connect

torch

according

Section

Make

sure

backup

and

all

gas

connections

are

securely

tightened.

With

regulator/flowmeter

valve

closed,

open

gas

cylinder

valve.

Turn

off

the

shielding

gas

and

coolant

supplies

their

sources.

L~~U~E

HIGH

CONCENTRATION

SHIELDING

GAS

can

harm

health

kill.



Shut

off

gas

supply

when

not

use.

HOT

and



Begin

welding.

-2.

SHUTTING

DOWN

Stop

welding.

OM-1559

Page

SECTION

MAINTENANCE

INSPECTION

AND

UPKEEP

Usage

and

shop

conditions

will

determine

frequency

and

type

maintenance

required.

Perform

inspections

once

week.

WARNING

_________

ELECTRIC

SHOCK

can

kill;

HOT

SURFACES

can

cause

severe

burns.



not

touch

live

electrical

parts.



Shut

down

we/ding

power

source

before

working

torch.



Disconnect

torch

from

welding

power

source

before

inspecting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

Inspect

torch

for

broken

areas,

cracks

and

loose

parts;

tighten,

repair

and

replace

required.

Remove

grease

and

dirt

from

components,

and

moisture

from

electrical

parts

and

cables.

Power

Cable

Inspect

cables

for

breaks

insulation,

and

ensure

that

all

connections

are

clean

and

tight.

Repair

replace

cables

insulation

breaks

are

present.

Clean

and

tighten

connections

each

inspection.

PREPARING

TUNGSTEN

ELECTRODES

(Figure

5-1)

t~Uiis1~

HOT

FLYING

METAL

PARTICLES

can

injure

personnel,

start

fires,

and

damage

equip

ment;

TUNGSTEN

CONTAMINATION

can

lower

weld

quality.



Shape

tungsten

electrode

only

with

properly

guarded

grinder

safe

location

wearing

proper

face,

hand,

and

body

protection.



not

use

same

wheel

for

any

other

job

the

tungsten

will

become

contaminated.

WARNING

_________

ELECTRIC

SHOCK

can

kill;

HOT

SURFACES

can

cause

severe

burns.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

before

working

torch.



Disconnect

torch

from

welding

power

source

before

inspecting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

Once

week

inspect

condition

torch

body

com

ponents.

Replace

cup,

heat

shield,

backcap,

and

0-rings

crack

ed.

Maintain

tight

fit

torch

components

ensure

good

wed

quaity.

-3.

INSPECTING

HOSES,

CONNECTIONS

AND

CABLES

WARNING

_________

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

disconnect

input

power

employing

lockout/tagging

pro

cedures

before

inspecting,

maintaini,?g,

ser

vicing.

Lockout/tagging

procedures

consist

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnecting

device.

Once

week

inspect

hoses

and

connections.

Tungsten

electrode

shaping

should

done

fine

grit,

hard

abrasive

wheel.

Since

tungsten

harder

than

most

grinding

wheels,

causing

the

tungsten

chip

ped

away

rather

than

cut

away,

the

grinding

marks

should

run

lengthwise

with

the

electrode.

For

additional

information,

see

your

distributor

quest

handbook

from

factory

the

Gas

Tungsten

Arc

Welding

(GTAW)

process.

Gas

Hose

TA-IZO

630

Gas

leaks

may

result

poor

weld

quality.

Inspect

hoses

for

breaks.

Keep

connections

clean

and

tight.

Figure

Tungsten

Preparation

-2.

TORCH

BODY

MAINTENANCE

(Figure

3-1)

TUNGSTEN

PREPARATION:

IDEAL

Stable

Arc

Straight

Ground

Flat

(the

DIa.

Flat

Governs

Amperage

Capacity)

TUNGSTEN

PREPARATION:

WRONG

Arc

Wander

~~~iiII

Point

Radial

OM-1

559

Page

Table

Tungsten

Size

Chart

Electrode

Diameter

Amperage

Range

Polarity

Gas

Type

Pure

Tungsten

(Green

Band)

DC-Argon

Electrode

Negative/

Straight

Polarity

DC-Argon

Electrode

Positive/

Reverse

Polarity

AC-Argon

Using

High

Frequency

.020

.040

1/16

3/32

1/8

5-20

15-80

70-150

125-225

225-360

10-20

15-30

25-40

5-20

10-60

50-100

100-160

150-210

Thorium

Alloyed

Tungsten

(Red

Band)

.020

.040

16

3/32

1/8

15-40

25-85

50-160

135-235

250-400

10-20

15-30

25-40

15-35

20-80

50-150

130-250

225-360

Zirconium

Alloyed

Tungsten

(Brown

Band)

020

040

1/16

3/32

1/8

15-35

20-80

50-150

130-250

225-360

NOT

RECOMMENDED

The

figures

are

intended

guide

and

are

composite

recommendations

from

American

Welding

Society

(AWS)

and

electrode

manufacturers.

Item

Miller

No.

Stock

No.

Model

No.

Description

HR NR

VHR

VNR

VHF

VNF

Figure

Complete

Torch

Assembly

116252

115

251

116

256

t119

914

t119

915

116

250

116253

TUNGSTEN,

electrode

(consult

your

welding

supply

distributor)

CUP

(see

Figure

COLLET

BODY

(see

Figure

TORCH

BODY,

rigid

w/heat

shield

(consisting

of)

TORCH

BODY,

flex

w/heat

shield

(consisting

of)

HEATSHIELD,std

HEAT

SHIELD,

small

dia

gas

lens

HEAT

SHIELD,

large

dia

gas

lens

TORCH

BODY,

rigid

w/heat

shield

valve

(con

sisting

of)

TORCH

BODY,

flex

w/heat

shield

valve

(con

sisting

of)

HEATSHIELD,

std

VALVE,

knob

(consisting

of)

0-RING

COLLET

(see

Figure

BACKCAP,

short

(consisting

of)

BACKCAP,

medium

(consisting

of)

BACKCAP,

long

(consisting

of)

1 1

Quantity

Model

300HS

3GHS

3GHSLD

116255

100VK

116254

100R

116259

300S

t116258

300M

t116

257

300L

OM-1

559

Page

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